Process to Remove Product Alcohol from a Fermentation by Vaporization under Vacuum

ABSTRACT

A fermentation liquid feed including water and a product alcohol and optionally CO 2  is at least partially vaporized such that a vapor stream is produced. The vapor stream is contacted with an absorption liquid under suitable conditions wherein an amount of the product alcohol is absorbed. The portion of the vapor stream that is absorbed can include an amount of each of the water, the product alcohol and optionally the CO 2 . The temperature at the onset of the absorption of the vapor stream into the absorption liquid can be greater than the temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid. The product alcohol can be separated from the absorption liquid whereby the absorption liquid is regenerated. The absorption liquid can include a water soluble organic molecule such as an amine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 13/023,134, filed on Feb. 8, 2011 which claims the benefit of U.S. Provisional Application No. 61/427,896, filed Dec. 29, 2010, and U.S. Provisional Application No. 61/302,695, filed Feb. 9, 2010, the entire disclosures of which are incorporated in their entirety herein by reference thereto.

FIELD OF THE INVENTION

The present invention relates to processes to remove butanol and other C₂ to C₈ alcohols from a fermentation broth employing vacuum vaporization.

BACKGROUND

Currently, much industrial fermentation involves the manufacture of ethanol for either chemical or fuels use. For use in fuel, butanol has advantages as compared to ethanol, namely butanol has a lower vapor pressure and decreased solubility in water.

An advantageous butanol fermentation process would encompass a complete, or substantially complete, conversion of sugars to butanol without reaching a butanol titer above a threshold of butanol tolerance that causes the rate of butanol production to fall below an undesirable predetermined rate. While it may be possible to limit sugar loadings to a level whereby batch fermentation does not require operation at a butanol concentration above the tolerance level, this approach has disadvantages because limited sugar loadings result in dilute solutions that are themselves economically undesirable to process. Therefore, there is a need for a process by which levels of butanol are limited in a fermentation at or below the tolerance level whilst sugar loadings are not limited by considerations of the tolerance level.

One means by which a butanol producing fermentation process might be made more efficient would be to remove the butanol as it is being formed from the fermentation medium (broth), so that the tolerance level of the butanol producing micro-organism is not reached, allowing high loading of sugar to be charged to the fermentation vessel. Such an “in situ product removal” or “ISPR” process is described in PCT International Publication No. WO2009/079362 A2.

ISPR processes for fermentation products are also described in the Roffler dissertation (Roffler, Steve Ronald, “Extractive fermentation—actic acid and acetone/butanol production,” Department of Chemical Engineering at the University of California at Berkeley, 1986). Roffler describes a process whereby a liquid stream from a fermentation vessel is passed to a separate vessel which is held under vacuum. However, the method described in Roffler necessitates further processing of the resulting vapor stream. Because an industrial fermentation relies on microorganisms, such processing must consider temperature constraints relative to the microorganisms.

To operate at acceptable temperatures, consideration must be given to costs and practicalities of cooling or operation under vacuum. The costs associated with removal of heat within a chemical process can be a function of the plant location and also the time of the year. In many geographic areas, it is not possible to guarantee cooling to be available or practical at the temperature at which heat needs to be removed from the vapor stream.

Providing chilled water to the heat exchanger by which condensation is carried out significantly increases the cost of the cooling medium. An alternative would be to compress the vapor stream to a higher pressure to allow the condensation to be done against cooling water year round, but this too entails significant cost because of the low density of the initial vapor passing to the machine. Processes described which use lithium bromide for absorption of ethanol and water vapors may not be adequate for absorbing carbon dioxide or higher alcohols of a vapor stream.

In addition, with whatever method is used, there will be a residual gas stream (due to the solubility of CO₂ in the fermentation broth) that must be compressed before discharge to the atmosphere. The residual gas stream will comprise CO₂. While vacuum flashing represents an effective means by which butanol can be removed from a fermentation process, there is a need for advances in the processing of the resulting low pressure vapor stream containing the product.

SUMMARY OF THE INVENTION

Methods of removing product alcohol from a fermentation by vaporization under vacuum are presented. For example, in some embodiments, a fermentation liquid feed comprising water and a product alcohol and optionally CO₂ is at least partially vaporized such that a vapor stream is produced. Methods of recovering a product alcohol from the vaporized fermentation feed are also presented. For example, in some embodiments, the vapor stream containing the product alcohol is contacted with an absorption liquid under suitable conditions wherein an amount of the product alcohol is absorbed. Also presented are methods of recovering a product alcohol from the absorption liquid whereby the absorption liquid is regenerated.

In embodiments, a method includes at least partially vaporizing a fermentation liquid feed wherein a vapor stream is produced, the fermentation liquid feed and the vapor stream each including an amount water, a product alcohol and optionally CO₂; and contacting the vapor stream with an absorption liquid under vacuum conditions wherein at least a portion of the vapor stream is absorbed into the absorption liquid to form an absorption liquid phase. The portion of the vapor stream that is absorbed can include an amount of each of the water, the product alcohol and optionally the CO₂. The temperature at the onset of the absorption of the vapor stream into the absorption liquid can be greater than the temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid.

In embodiments, partially vaporizing the fermentation liquid can include removing the fermentation liquid feed from a fermentation vessel; supplying the fermentation liquid feed to a multi-stage distillation column at a suitable flow rate; distilling the fermentation liquid feed to produce the vapor stream enriched in the product alcohol and a bottoms stream depleted in the product alcohol, wherein the distilling occurs under a pressure sufficiently below atmospheric to allow for the vapor stream to be produced at a temperature no greater than about 45° C.; and optionally, returning any portion of the bottoms stream to the fermentation vessel. In some embodiments, the concentration of the product alcohol in the bottoms stream is not more than 90% of the concentration of the product alcohol in the fermentation liquid feed.

In some embodiments, a titer of product alcohol in a fermentation vessel can be maintained below a preselected threshold pursuant to methods presented herein. For example, a method can include removing from a fermentation vessel a fermentation liquid feed stream comprising product alcohol, water, and optionally CO₂; supplying the fermentation liquid feed stream to a single stage flash tank or a multi-stage distillation column; vaporizing under vacuum conditions the fermentation liquid feed stream in the single stage flash tank or the multi-stage distillation column to produce a vapor stream enriched in product alcohol and a bottoms stream depleted in product alcohol; and optionally returning any portion of the bottoms stream to the fermentation vessel. In some embodiments, the vapor stream is contacted with an absorption liquid under vacuum conditions wherein at least a portion of the vapor stream is absorbed into the absorption liquid.

In some embodiments of the methods presented herein, the fermentation liquid feed includes CO₂. In some embodiments, the product alcohol is butanol. In some embodiments, the absorption liquid comprises a water soluble organic molecule different from the product alcohol. In some embodiments, the organic molecule is an amine such as monoethanolamine (MEA), 2-amino 2-methyl propanol (AMP), methyldiethanolamine (MDEA), or a mixture thereof. In embodiments, the absorption liquid phase includes a water soluble organic molecule with a boiling point at least 30° C. greater than the boiling point of water. In embodiments, the absorption liquid comprises potassium carbonate and ethylene glycol. In embodiments, the absorption liquid comprises ethylene glycol.

In some embodiments, a substantial portion of the CO₂ and at least a portion of the product alcohol or water or both are absorbed into absorption liquid.

Also provided herein is a method of recovering a product alcohol from an absorption liquid phase and regenerating the absorption liquid phase. Recovering the product alcohol may include pumping from an absorber an absorption liquid phase including an absorption liquid, water, product alcohol, and optionally CO₂, to a higher pressure than a pressure in the absorber; optionally, heating the absorption liquid phase; feeding the absorption liquid phase to a multi-stage distillation column comprising a stripping section and optionally a rectification section; operating the distillation column under conditions such that a bottoms product comprising the absorption liquid and a vapor phase comprising a mixture of water, product alcohol, and optionally CO₂ are produced; recovering the bottoms product comprising the absorption liquid phase from the distillation column; and recovering the water, the product alcohol and optionally CO₂ from the vapor phase.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

FIG. 1 illustrates an example system useful for practicing processes according to embodiments described herein.

FIG. 2 is a schematic of the static cell PtX apparatus as described in Example 1.

FIG. 3 is a graph of the peak height vs. CO₂ absorbed spectra for a monoethanolamine solution as described in Example 6.

FIG. 4 is a graph of CO₂ absorbed vs. peak height as described in Example 6.

FIG. 5 is a graph of temperature vs. peak height as described in Example 6.

FIG. 6A is an example flow diagram for an embodiment of the processes provided and is referenced in Example 7.

FIGS. 6B and 6C illustrate Tables 8A and 8B, respectively, which summarize simulation model results of Example 7.

FIG. 7A is an example flow diagram for an embodiment of the processes provided and is referenced in Example 8.

FIGS. 7B and 7C illustrate Tables 10A and 10B, respectively, which summarize simulation model results of Example 8.

FIG. 8A is an example flow diagram for an embodiment of the processes provided and is referenced in Example 9.

FIGS. 8B and 8C illustrate Tables 12A and 12B, respectively, which summarize simulation model results of Example 9.

FIG. 9 illustrates an example system useful for practicing processes according to embodiments described herein.

FIGS. 10A, 10B and 10C illustrate an example system useful for practicing processes according to embodiments described herein, and specifically for demonstrating air stripping before vacuum flash.

DETAILED DESCRIPTION

The processes provided herein can be more fully understood from the following detailed description and accompanying figures which form a part of this application. Reference made to figures is intended to aid in the understanding of the processes described herein, and should not be construed as limiting. In addition, where process conditions are proposed in reference to a figure, these are supplied as an example and variation from these conditions is within the spirit of the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present application including the definitions will control. Also, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. All publications, patents and other references mentioned herein are incorporated by reference in their entireties for all purposes.

In order to further define this invention, the following terms and definitions are herein provided.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains” or “containing,” or any other variation thereof, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. For example, a composition, a mixture, a process, a method, an article, or an apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

As used herein, the term “consists of,” or variations such as “consist of or “consisting of,” as used throughout the specification and claims, indicate the inclusion of any recited integer or group of integers, but that no additional integer or group of integers may be added to the specified method, structure, or composition.

As used herein, the term “consists essentially of,” or variations such as “consist essentially of or “consisting essentially of,” as used throughout the specification and claims, indicate the inclusion of any recited integer or group of integers, and the optional inclusion of any recited integer or group of integers that do not materially change the basic or novel properties of the specified method, structure or composition.

Also, the indefinite articles “a” and “an” preceding an element or component of the invention are intended to be nonrestrictive regarding the number of instances, i.e., occurrences of the element or component. Therefore “a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

The term “invention” or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.

As used herein, the term “about” modifying the quantity of an ingredient or reactant of the invention employed refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or solutions in the real world; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients employed to make the compositions or to carry out the methods; and the like. The term “about” also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Whether or not modified by the term “about”, the claims include equivalents to the quantities. In one embodiment, the term “about” means within 10% of the reported numerical value, alternatively within 5% of the reported numerical value.

“Biomass” as used herein refers to a natural product comprising hydrolysable polysaccharides that provide fermentable sugars, including any sugars and starch derived from natural resources such as corn, sugar cane, wheat, cellulosic or lignocellulosic material and materials comprising cellulose, hemicellulose, lignin, starch, oligosaccharides, disaccharides and/or monosaccharides, and mixtures thereof. Biomass may also comprise additional components, such as protein and/or lipids. Biomass may be derived from a single source, or biomass can comprise a mixture derived from more than one source; for example, biomass may comprise a mixture of corn cobs and corn stover, or a mixture of grass and leaves. Biomass includes, but is not limited to, bioenergy crops, agricultural residues, municipal solid waste, industrial solid waste, sludge from paper manufacture, yard waste, wood and forestry waste. Examples of biomass include, but are not limited to, corn grain, corn cobs, crop residues such as corn husks, corn stover, grasses, wheat, rye, wheat straw, barley, barley straw, hay, rice straw, switchgrass, waste paper, sugar cane bagasse, sorghum, soy, components obtained from milling of grains, trees, branches, roots, leaves, wood chips, sawdust, shrubs and bushes, vegetables, fruits, flowers, animal manure, and mixtures thereof. For example, mash or juice or molasses or hydrolysate may be formed from biomass by any processing known in the art for processing the biomass for purposes of fermentation, such as by milling, treating and/or liquefying and comprises fermentable sugar and may comprise an amount of water. For example, cellulosic and/or lignocellulosic biomass may be processed to obtain a hydrolysate containing fermentable sugars by any method known to one skilled in the art. Particularly useful is a low ammonia pretreatment as disclosed US Patent Application Publication US20070031918A1, which is herein incorporated by reference. Enzymatic saccharification of cellulosic and/or lignocellulosic biomass typically makes use of an enzyme consortium for breaking down cellulose and hemicellulose to produce a hydrolysate containing sugars including glucose, xylose, and arabinose. (Saccharification enzymes suitable for cellulosic and/or lignocellulosic biomass are reviewed in Lynd, L. R., et al. (Microbiol. Mol. Biol. Rev., 66:506-577, 2002).

The term “vacuum flash” or “flash” refers to a process step whereby a liquid stream from a fermentation vessel is passed to a separate vessel (which can be a multi-stage distillation column or a single-stage tank) which is held under vacuum. The reduction in pressure causes a fraction, typically no more than 10%, of the liquid stream to flash into the vapor phase. A liquid stream subjected to this step may be referred to as “flashed” or “partially vaporized” or “vaporized”. In embodiments where the “flash” is carried out in a multi-stage distillation column, the flash may also be referred to as a “distillation” or a “flash distillation.”

The term “vacuum flash vessel” refers to the physical location in which at least a fraction of the liquid stream from the fermentation vessel flashes into the vapor phase.

The term “absorption liquid” as used herein refers to a liquid introduced into the process which is capable of absorbing any portion of the vapor phase produced during the flash.

The term “fermentation” as used herein refers to a process step whereby a carbon substrate is converted into a product, such as a product alcohol, by the action of microorganisms.

The term “fermentation broth” or “fermentation liquid” as used herein refers to the mixture of water, sugars, dissolved solids, microorganisms producing alcohol, product alcohol and all other constituents of the material held in the fermentation vessel in which product alcohol is being made by the reaction of sugars to alcohol, water and carbon dioxide (CO₂) by the microorganisms present. From time to time, as used herein the term “fermentation medium” and “fermented mixture” can be used synonymously with “fermentation broth”.

“Fermentable carbon source” as used herein means a carbon source capable of being metabolized by the microorganisms disclosed herein for the production of fermentative alcohol. Suitable fermentable carbon sources include, but are not limited to, monosaccharides, such as glucose or fructose; disaccharides, such as lactose or sucrose; oligosaccharides; polysaccharides, such as starch or cellulose; carbon substrates; and mixtures thereof. From time to time, as used herein the term “fermentable carbon source” can be used synonymously with “carbon substrate” or “fermentable carbon substrate”. The carbon source includes carbon-derived from biomass.

“Feedstock” as used herein means a feed in a fermentation process, the feed containing a fermentable carbon source with or without undissolved solids, and where applicable, the feed containing the fermentable carbon source before or after the fermentable carbon source has been liberated from starch or obtained from the break down of complex sugars by further processing, such as by liquefaction, saccharification, or other process. Feedstock includes or is derived from a biomass. Suitable feedstock include, but are not limited to, rye, wheat, corn, cane and mixtures thereof.

“Sugar” as used herein refers to oligosaccharides, disaccharides and/or monosaccharides.

“Fermentable sugar” as used herein refers to sugar capable of being metabolized by the microorganisms disclosed herein for the production of fermentative alcohol.

The term “product alcohol” as used herein refers to a lower alkane alcohol, such as a C₂-C₈ alcohol produced as a primary product by a microorganism in a fermentation process.

“Butanol” as used herein refers to the butanol isomers 1-butanol (1-BuOH), 2-butanol (2-BuOH) and/or isobutanol (iBuOH or i-BuOH or I-BUOH), either individually or as mixtures thereof.

The term “recombinant microorganism” as used herein refers to a microorganism that has been engineered using molecular biological techniques. The microorganism can be optionally engineered to express a metabolic pathway, and/or the microorganism can be optionally engineered to reduce or eliminate undesired products and/or increase the efficiency of the desired metabolite.

“Substantial portion” as used herein with reference to a process stream or a component thereof, refers to at least about 50% of the indicated process stream or indicated component thereof. In embodiments, a substantial portion may comprise about at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 95% or the indicated process stream or indicated component thereof.

“Any portion” as used herein with reference to a process stream refers to any fractional part of the stream which retains the composition of the stream, including the entire stream, as well as any component or components of the stream, including all components of the stream.

Provided herein are methods by which a fermentation liquid stream leaving a fermentation vessel is processed using a vacuum flash. The vacuum flash can be carried out in a single stage flash tank. Alternatively or in conjunction, the vacuum flash can be carried out in a multi-stage distillation column under conditions such that a flashed fermentation broth forms a vapor stream enriched in product alcohol and a bottoms stream substantially depleted in product alcohol are produced. As disclosed herein, the vapor stream from the flashed fermentation broth can be absorbed into a second liquid stream at a higher temperature than it could be condensed on its own. Such processes are useful for fermentations which produce product alcohols, and, in particular butanol, because of the desire to remove butanol during fermentation to diminish impact on productivity and/or viability of the microorganisms in the fermentation. Processes are therefore provided which provide for effective product recovery during fermentation with minimized impact on the optimal fermentation conditions.

During a product alcohol fermentation, the product alcohol is produced in a fermentation liquid by a microorganism from a carbon substrate. In embodiments, the carbon substrate is provided in a mash derived from a plant source. The fermentation can be carried out under conditions known to those of skill in the art to be appropriate for the microorganism. In embodiments, the fermentation is carried out at temperatures of from about 25° C. to about 40° C. In embodiments, the fermentation is carried out at temperatures of from about 28° C. to about 35° C. and in embodiments, from about 30° C. to about 32° C. The fermentation liquid comprises water and a product alcohol, and typically, CO₂. To recover the product alcohol from the liquid using the methods provided herein, at least a portion of the fermentation liquid is removed from the fermentation vessel to a second vessel or “vaporization vessel” and is at least partially vaporized by vacuum flash. For example, in such embodiments, the vaporization can take place at temperatures of from about 25 to about 60° C. under vacuum. The vaporization can take place at pressures from about 0.02 to about 0.2 bar. It will be appreciated that the pressure can be 0.02, 0.03, 0.04, 0.05, 0.1, 0.15 or 0.2 bar, or less than about 0.2 bar. In embodiments, the vaporization can take place at pressures of from about 0.05 to about 0.2 bar. In embodiments, the vaporization can take place at a pressure of less than about 0.2 bar, or less than about 0.1 bar. Alternatively, the vacuum flash can be carried out in a multi-stage distillation column as described elsewhere herein under conditions described herein.

It is desirable for the vaporization to be initiated and carried out during the fermentation process such that product alcohol is removed at about the same rate at which it is produced. It will be appreciated that the vaporization will be carried out at a rate and under conditions such that the product alcohol in the fermentation vessel is maintained below a preselected threshold. The preselected threshold will depend on the tolerance of the microorganism to the product. In embodiments, the microorganism is bacteria, cyanobacteria, filamentous fungi, or yeasts. In some embodiments, the bacteria are selected from the group consisting of Zymomonas, Escherichia, Salmonella, Rhodococcus, Pseudomonas, Bacillus, Lactobacillus, Enterococcus, Pediococcus, Alcaligenes, Klebsiella, Paenibacillus, Arthrobacter, Corynebacterium, and Brevibacterium. In some embodiments the yeast is selected from the group consisting of Pichia, Candida, Hansenula, Kluyveromyces, Issatchenkia, and Saccharomyces. In embodiments, the threshold is less than about 20 g/L. In embodiments, the threshold is below about 8 g/L, below about 10 g/L, below about 15 g/L, below about 25 g/L, below about 30 g/L, or below about 40 g/L. Further, microorganisms, such as recombinant microorganisms, modified to have certain characteristics to benefit the production and recovery of a product alcohol are contemplated herein. For example, a microorganism with a certain level of thermotolerance such that elevated fermentation or feed stream temperatures may be more tolerated and therefore provide overall process efficiency. Further, where a fermentative microorganism performs advantageously under certain conditions characteristically, the processes described herein can be utilized to capitalize on such efficiencies. For example, a gas stripper may be used to provide effective air stripping and to provide oxygen for microoaerobic microorganisms in the fermentation vessel.

Processes described herein can be used in conjunction with a number of product alcohols. Such alcohols include, but are not limited to, lower alkane alcohols such as butanol. In embodiments, the processes described herein involve production of butanol by a recombinant microorganism capable of converting a carbon substrate to butanol. Microorganisms capable of converting a carbon substrate to butanol are known in the art and include, but are not limited to, recombinant microorganisms such as those described in U.S. Patent Application Publication Nos. 2007/0092957 and 2009/0305363, in U.S. Provisional Application Ser. Nos. 61/379,546, 61/380,563, and in U.S. Nonprovisional application Ser. No. 12/893,089.

With regard to a butanol-producing fermentation, the composition of the stream that leaves the fermentation vessel is typically largely water, and contains the product butanol and CO₂. For certain processes described herein, the vapor stream is contacted with an absorption liquid in an absorber. In contrast to processes used in the art to treat gas streams that contain acid gasses such as CO₂ and H₂₅ by absorption into specially designed absorption media (Gas Purification, 5th Edition, Arthur Kohl and Richard Neilsen 1997), the methods discovered by the applicants and provided herein seek to absorb any or all components of the vapor stream via the absorption medium. The absorption liquid will absorb water at a higher temperature than the water would normally condense. Furthermore, in some embodiments, the product alcohol is also soluble in the absorption liquid. While in embodiments of the process, the three components water, butanol, and CO₂ are all absorbed in the absorption medium, embodiments comprising absorption of any portion of the vapor stream to produce a residual vapor stream that is product alcohol rich or CO₂ rich to be further processed still provide advantages to a vacuum flash fermentation process.

Also, in contrast to processes used in the art to treat gas streams, the contact with the absorption liquid takes place at a sub-atmospheric pressure close to that of operation of the flash, and in embodiments substantially all of the vapor stream is absorbed. The flash and absorption units can be coupled in such a way as to minimize pressure drop between the two operations.

To recover the product alcohol, the heat of absorption is removed from the absorption liquid, for example, by circulation over a cooler. In such an embodiment, the heat can be removed from the circulating fluid using a cheaper cooling medium than would be required for condensation of the vapor stream without an absorption liquid, the cheaper cooling typically being via an air cooler or a heat exchanger operating from a cooling water circuit or using river water directly. The amount of absorption fluid that would need to be re-circulated depends on the temperature rise that can be allowed over the absorber, which can be an absorption column. The upper temperature in the absorber is limited by vapor pressures from the solution at the pressure of absorption whilst the lower temperature is limited by approach to the cold utility temperature, normally cooling water.

For processes provided herein, contact of the vapor stream with an absorption liquid is carried out under a vacuum, and can be carried out at pressures of from about 0.02 to about 0.2 bar. In embodiments, the contacting can take place at a pressure of less than about 0.2 bar, or less than about 0.1 bar. The contacting can be carried out at temperatures of from about 25° C. to about 60° C. In embodiments, the vaporization step and the contacting step are carried out at the same pressure.

Suitable absorption liquids include those that comprise a water soluble organic molecule. In embodiments, the water soluble organic molecule has a boiling point at least 30° C. greater than the boiling point of water. In embodiments, the organic molecule is an amine. In embodiments, the amine is mono ethanolamine (MEA), 2-amino 2-methyl propanol (AMP) or methyldiethanolamine (MDEA). In embodiments, the molar ratio of absorption liquid amine to CO₂ in the vapor stream is at least about 1.01 to about 1, i.e., the molar ratio is greater than about 1. In embodiments, the absorption liquid comprises MEA, AMP, MDEA, or any mixture thereof. The absorption liquid can comprise an ionic solution. In embodiments, the ionic solution comprises a carbonate. In embodiments, the carbonate is potassium carbonate because of its higher solubility compared to other common alkali metal carbonates. In embodiments, the amount of carbonate (e.g., potassium carbonate) in the ionic solution is an amount sufficient for achieving absorption of at least a portion (or in embodiments, a substantial portion) of CO₂ from the vapor stream. In embodiments, the molar ratio of carbonate (e.g., potassium carbonate) to CO₂ in the vapor stream is greater than about 1.

In embodiments, the absorption liquid is an ionic liquid. Suitable absorption liquids for absorption of both water and butanol include those with the following characteristics: 1) miscible with water and butanol, 2) normal boiling point of 130° C. or more, or of 150° C. or more, 3) thermal stability at the boiling point, 4) absence of precipitants when exposed to carbon dioxide at a ratio less than 5% weight/weight, or 10% weight/weight, and 5) low corrosivity.

While not wishing to be bound by theory, it is believed that absorption liquids in which at least water will absorb will convey an improvement on the state of the art, provided the temperature of onset of absorption is greater than the temperature of onset of condensation without the material.

In embodiments, the methods provided herein use MEA as the absorption liquid. MEA solutions in the processes absorb water at a higher temperature than water would condense without the presence of the MEA solution. Additionally, butanol is soluble in the MEA solution and the MEA solution is also capable of absorbing CO₂.

In embodiments, the methods provided herein use MDEA as the absorption liquid. MDEA solutions in the processes absorb water at a higher temperature than water would condense without the presence of the MDEA solution. Additionally, butanol is soluble in the MDEA solution and the MDEA solution is also capable of absorbing CO₂. Whilst other amines could be used, MDEA also has the advantage that it does not form a carbamide and is therefore readily regenerated.

Suitable absorption liquids include, but are not limited to hygroscopic organic liquids, high-boiling organic amines, and ionic liquids, as well as biologically-derived liquids of the above, or mixtures thereof,

Hygroscopic Organic Liquids.

Suitable hygroscopic organic liquids contain components which are soluble in water and water is soluble in the organic component. These liquids have a higher boiling point than water to facilitate absorption of water at a higher temperature than the condensation point of water. Typically these molecules will require at least two functional groups on their carbon backbones such as glycols and diacids. As examples, the absorption liquid can include ethylene glycol, ethylene glycol monomethyl ether, diethylene glycol, propylene glycol, dipropylene glycol, polyethylene glycols, polyethylene glycol ethers, polypropylene glycol ethers, or a mixture thereof. Biologically-derived 1,3-pronaediol may also be used and may provide overall carbon-footprint benefit. See e.g., U.S. Pat. No. 7,759,393. Moreover,

As water is readily soluble in for example, ethylene glycol, hygroscopic organic liquids provide for absorption from the vapor phase. Further, the solubility of butanol in these liquids (and in particular ethylene glycol) is better than in water. In some preferred embodiments, the hygroscopic organic liquid may also form an ionic solution. An example is potassium carbonate in ethylene glycol solution.

High-Boiling Organic Amines.

High boiling organic amines, such as alkanolamines, are suitable for use with the processes described herein. Like ethylene glycol, alkanolamines such as MEA and MDEA are miscible with water and facilitate absorption of water at a high temperature. They are also more miscible with butanol than butanol is with water. In addition, they absorb CO₂ absorption through a heat-reversible reaction.

In embodiments, the absorption liquid includes a polyethylenimine or related polymeric amino system.

By way of non limitative example, amines that can serve as absorption liquids for use with the processes described herein can include aliphatic or cycloaliphatic amines having from 4 to 12 carbons, alkanolamines having from 4 to 12 carbons, cyclic amines where 1 or 2 nitrogens together with 1 or 2 alkanediyl groups form 5-, 6- or 7-membered rings, mixtures of the above solutions, and aqueous solutions of the above mixtures and solutions.

For example, the absorption liquid can include monoethanolamine (MEA), methylaminopropylamine (MAPA), piperazine, diethanolamine (DEA), triethanolamine (TEA), diethylethanolamine (DEEA), diisopropylamine (DIPA), aminoethoxyethanol (AEE), dimethylaminopropanol (DIMAP) and methyldiethanolamine (MDEA), any mixture thereof, or any aqueous solutions thereof.

Ionic Liquids.

Ionic liquids are solutions comprising a cation and/or an anion, such as a variety of salts that are in solution at a temperature below 100° C. Examples of suitable ionic liquids include those described in U.S. Patent Application Publication Nos. 2010/0143993, 2010/0143994, and 2010/0143995, incorporated herein by reference. The presence of inorganic salts cause a reduction in the vapor pressure of water in the solution both by dilution and the increased ionization of water. Water-soluble salts are suitable for this process. Suitable for embodiments wherein water is absorbed are solutions comprising salts that are highly soluble in water, such as lithium bromide. Generally, the monovalent alkali metals, such as lithium, sodium, potassium will be chosen over other metals because of an increased solubility. The correct choice of anion can allow CO₂ to also be recovered in the process. Carbonate ion can be employed to absorb CO₂ in the aqueous phase by formation of the bicarbonate ion. Processes using potassium carbonate solutions are generally referred to as the Benfield Process which, prior to the disclosure herein, has not been used in conjunction with alcohol production fermentations to provide a temperature advantage for recovery of a fermentation product alcohol. In embodiments, a mixed salt solution such as potassium carbonate and a potassium halide salt can be employed. While not wishing to be bound by theory, it is believed that such a mixed salt solution will increase the ionic strength of the solution to improve capture of water without causing precipitation of salts. It is noted that ionic liquids may absorb ethanol water and/or CO₂ from the vapor phase more efficiently than higher alcohols such as butanol (i.e., a C3 or higher product alcohol) as well as it can absorb ethanol.

The temperature at the onset of the absorption of the vapor stream into the absorption liquid phase is greater than the temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid phase. The temperature of onset of absorption or condensation can be assessed by calculation using standard vapor liquid equilibrium methods that are based on experimental data or by direct measurement from the process. In embodiments, the temperature at the onset of the absorption of the vapor stream into the absorption liquid phase is greater than the temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid phase by at least about 2° C.; in embodiments, at least about 3° C.; in embodiments, at least about 5° C.; in embodiments, at least about 10° C.; in embodiments, at least about 15° C.; in embodiments, at least about 20° C.; and in embodiments, at least about 30° C. Equipped with this disclosure, one of skill in the art will be readily able to use the processes described herein to minimize the cost of cooling plus the cost of regenerating the solvent.

It will be appreciated that it is beneficial to absorb as much of the vapor stream as possible into the absorption liquid. In embodiments, at least about 50% of the vapor stream is captured by the absorption liquid. In embodiments, at least about 60%, at least about 70%, at least about 80%, at least about 90% or at least about 99% of the vapor stream is absorbed into the absorption liquid. In embodiments, the vapor stream comprises about 50-65% by mass of water, about 30-35% by mass of butanol, and about 2-20% by mass CO₂. It will be appreciated that absorption, condensation and similar processes are made easier by establishing a high mass ratio of butanol to carbon dioxide. This ratio is on the order of 1 to 2 parts butanol to 100 parts carbon dioxide for the fermentation vessel vent. In embodiments, this ratio is increased to 1 to 5 parts butanol to 1 part carbon dioxide. In embodiments, this ratio is increased to 5 to 30 parts butanol to 1 part carbon dioxide. In embodiments, this ratio is increased to 10 to 100 parts butanol to 1 part carbon dioxide.

It will be further appreciated that recovery of butanol will be made easier to recover by condensation from a stream of a high ratio of butanol to water at pressures greater than 0.5 psig. In embodiments, this pressure is increased to 1 to 30 psig. In embodiments, this pressure is increased to 0.9 to 1.2 atmospheres.

In embodiments, the absorption liquid absorbs a substantial portion of the CO₂ from the vapor stream. In embodiments, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 95%, or at least about 99% of the CO₂ is absorbed. For such embodiments, the absorption liquid can be MEA, MDEA, AMP or ethylene glycol mixed with potassium carbonate.

Thus, provided herein is a process comprising: partially vaporizing a fermentation liquid comprising water and a product alcohol and optionally CO₂ wherein a fermentation vapor stream is produced; and contacting the fermentation vapor stream with an absorption liquid phase wherein any portion of the vapor stream is absorbed into the absorption liquid phase.

In embodiments where product alcohol is absorbed into the absorption liquid, the product alcohol can be recovered from the absorption liquid such that the absorption liquid is concurrently regenerated and recycled. The recovery and regeneration can be achieved using a process comprising: pumping an absorption liquid to a higher pressure than the vaporization and absorption took place, such as at a pressure at or above atmospheric pressure, which would allow venting of residual CO₂ from the process; feeding the absorption liquid to a distillation column comprising a stripping section and optionally a rectification section; distilling the absorption liquid such that a bottoms liquid product and a tops vapor product are produced; and recovering the bottoms product comprising the absorption liquid phase from the recovery distillation column. The feed to the recovery distillation column can be preheated to reduce the energy input required to the base of the recovery distillation column using techniques well known to those skilled in the art.

The components removed from the absorption liquid phase and recovered in the tops vapor product from the recovery distillation can be further separated using conventional methods such as condensation, distillation and decantation, or a combination thereof. Depending on the composition of the fermentation vapor stream and the absorption liquid employed, in embodiments, the absorption liquid, post vapor stream contact, will contain a combination of water, product alcohol and, optionally, CO₂ and in certain embodiment all three components.

FIG. 1 depicts an exemplary configuration of equipment, heat exchangers, and product streams for an embodiment of a process 100 described herein. A fermentation to produce butanol (or, in embodiments, other product alcohol(s)) is performed in a fermentation vessel 110, and the concentration of butanol in fermentation vessel 110 approaches the tolerance level of the microorganism. Fermentation liquid is purged from fermentation vessel 110 via a stream 124 to a vacuum flash vessel 210 to facilitate the removal of butanol. In some embodiments, vacuum flash vessel is a flash tank, and the pressure in vessel 210 is maintained at such a pressure that in combination with heat that is supplied in the form of partially vaporized water in a stream 216, a sufficient purge of butanol is achieved in a vapor stream 212 so as to permit butanol levels in vessel 110 to be maintained below a preselected threshold given that the remaining liquid from vacuum flash vessel 210 is returned to fermentation vessel 110 via a stream 214.

The pressure in vessel 210 can be sufficiently low to achieve the cooling necessary to keep remaining liquid stream 214 and vessel 110 at a temperature acceptable to maintain productivity of the microorganism. The operating pressure of vessel 210 can be between 0.05 and 0.2 bar. It will be appreciated that the pressure can be 0.05, 0.1, 0.15 or 0.2 bar or less than about 0.2 bar. In embodiments, the ratio of the concentration of butanol in stream 214 to the concentration of butanol in stream 124 is about 0.9 to about 0.5. It will be appreciated that the ratio can be about 0.9, about 0.8, about 0.7, about 0.6, or about 0.5. Vapor stream 212 comprises water, butanol and CO₂. Stream 212 enters an absorption column 310 where it is contacted with absorption liquid streams 320 and 324. Absorption liquid streams 320 and 320 comprise an absorption liquid.

In a non-limiting example, the absorption liquid is an amine, such as MDEA. In a non-limiting example, the absorption fluid is potassium carbonate in ethylene glycol. The temperature and absorbent concentrations of 320 and 324 are maintained at such a level that vapor stream 212 is substantially absorbed. In embodiments, vapor stream 212 is substantially absorbed at a temperature of more than about 36° C. while the dew point of stream 212 is less than about 30° C. Residual vapor is removed via a vacuum system via stream 328 and will exit to a plant scrubbing system. There is a liquid recycle stream 322 drawn from the bottom of column 310 and cooled in a cooler 301 to produce a stream 324 which is circulated back to column 310. In some embodiments, a flow rate of stream 322 will be selected such that the temperature rise between streams 324 and 322 will be about 3° C. to about 8° C. A liquid purge is taken from column 310 via a stream 326, which includes the absorption liquid and CO₂, butanol and water absorbed from vapor stream 212. Stream 326 is pumped (pump not shown) to raise its pressure to approximately atmospheric or higher, and is optionally heated in a heater 311 to produce a stream 330. Heater 311 can conveniently be heat integrated with a cooler 302 as discussed below.

Stream 330 enters a stripping column 410 which comprises a stripping section and a rectification section using contacting devices known to those of skilled in the art. In the stripping section, CO₂, butanol and a substantial fraction of the water is stripped from the absorption liquid of stream 330. In embodiments, the pressure in stripping column 410 is approximately atmospheric and the bottom of stripping column 410 is heated to a temperature sufficient to assure that substantially all of the butanol is stripped and the water content of a liquid phase stream 432 including regenerated absorption liquid does not change over time. In embodiments, the water concentration of liquid phase 432 exiting the bottom of column 410 is 10%-40% by mass. Material is circulated from the bottom of column 410 via a stream 434. Stream 434 passes to a heater 413 to produce a stream 436 which is returned to vessel 410. In embodiments, the configuration of heater 413 can be of a kettle or thermosyphon readily designed by a person skilled in the art.

Regenerated absorption liquid is pumped (pump not shown) from the bottom of vessel 410 via stream 432, which can first be optionally cooled prior to introduction to absorption column 310. As shown in FIG. 1, in embodiments, regenerated absorption liquid stream 432 is cooled in cooler 302 to produce a stream 333. As mentioned above, cooler 302 can conveniently be heat integrated with heater 311 for cooling stream 432. Steam 333 can then optionally be further cooled via cooler 303 to produce cool absorption liquid stream 320. In embodiments, a side stream purge is taken from the rectification section of stripping column 410 via a stream 438. Stream 438 can be substantially free of absorption liquid and CO₂ and can contain about 1-3% butanol with the remainder being water. The water that is contained in stream 330 is substantially removed, via streams 438 and 432, from the downstream part of the process which includes column 410 and later-described decanter vessel 510 and butanol column 610. Control of stream 438 is such as to achieve the desired water level in stream 432. Stream 438 passes to a heater 411 and will be partially vaporized to form stream 216 which is fed to flash vessel 210. As described above, heat from stream 216 can help achieve the balance between vessel 210 and vessel 110 so as to effect a sufficient purge of butanol from fermentation liquid feed 124 via vapor stream 212 so as to permit butanol levels in vessel 110 to be maintained below a preselected threshold. In embodiments, heater 411 can conveniently be heat integrated with cooler 404.

Vapor leaves the top of stripping column 410 via a stream 440 and passes to a cooler 404 and separator 505 by which stream 440 is substantially condensed and separated from a residual vapor stream 442 to produce a liquid stream 444. Stream 440 can be substantially free of absorption liquid because of the action of the rectification section in stripping column 410. Residual vapor stream 442 passes to a plant scrubbing system (not shown). Stream 442 includes a major part of the CO₂ fed to stripping column 410, while a major part of the water and butanol of stream 440 is condensed to form stream 444. Cooler 404 can be conveniently heat integrated with heater 411 and a heater 614 (further discussed below).

Liquid stream 444 passes to a decanter vessel 510, which also receives a stream 652 discussed below. Material in decanter vessel 510 will split into an aqueous liquid phase 546 and an organic liquid phase 548. In embodiments, the aqueous phase or a portion thereof can be returned to the top of the rectification section of vessel 4 via stream 546. In embodiments, a portion of either or both of stream 546 and stream 438 (discussed above) can be directed to a beer column (not shown).

The organic phase from decanter vessel 510 leaves via stream 548 and passes to a butanol column 610, which comprises at least a stripping section. Heat is provided to operate column 610 via a re-circulating loop of a stream 656 through heater 614 to produce a stream 658, which is returned to column 610. In embodiments, the configuration of heater 614 can be of a kettle or thermosyphon readily designed by a person skilled in the art. If the operating pressure of column 610 is sufficiently below that of column 410 and cooler 404, then heater 614 can be conveniently heat integrated with cooler 404. The butanol product is taken from the bottom of column 610 via a stream 654. A vapor overhead stream 650 from column 610 passes to a cooler 405 and is condensed to produce stream 652. Stream 652 is pumped to decanter vessel 510 (pump not shown) where it can be split into aqueous and organic liquid phases.

In embodiments, vacuum flash vessel 210 for achieving vaporization of fermentation liquid stream 124 is a multi-stage distillation column 210, instead of a flash tank as described above (which has only one stage). In such embodiments, fermentation liquid feed 124 containing product alcohol is supplied from fermentation vessel 110 at a flow rate to multi-stage distillation column 210. Fermentation liquid feed 124 is then partially vaporized in distillation column 210 to produce vapor stream 212 enriched in product alcohol and bottoms stream 214 depleted in product alcohol. In contrast to vaporization carried out in a flash tank as described above, the multi-stage distillation column can be operated such that the vapor is subjected to more than one stage. The multi-stage distillation column can have any number of stages from 2 to 8 or more. In embodiments, the distillation column is a 6-stage column. As one of skill in the art will appreciate, this leads to a reduced concentration of product alcohol in bottoms stream 214 (which, in some embodiments, is returned to fermentation vessel 110, as shown in FIG. 1). Because product alcohol can be removed from fermentation vessel 110 more efficiently using distillation column 210 for the vaporization, the flow rate to the distillation column can be lower than the flow rate to a single-stage vacuum flash tank and still provide for sufficient removal of product alcohol from fermentation vessel 110. A lower flow rate from fermentation vessel 110 allows for venting of a greater fraction of CO₂ from the fermentation vessel, thereby lowering the flow rate of vented carbon dioxide by about 2 to about 5 times or more, and therefore provides for reduced CO₂ in streams subjected to further processing. Similarly, in embodiments wherein alcohol-depleted bottoms stream 214 or a portion thereof is returned to fermentation vessel 110, more efficient removal of product alcohol from fermentation liquid feed stream 124 allowing for decreased flow rate to multi-stage distillation column 210 likewise allows for a decrease in the flow rate of bottoms stream 214 back to the fermentation vessel. In this configuration, it is possible to return a bottoms stream of higher temperature to the fermentation vessel without disturbing the temperature of the fermentation beyond acceptable ranges, therefore allowing for the multi-stage distillation column to be operated at higher temperature than would otherwise be considered acceptable for a conventional single-stage vacuum flash tank.

Multi-stage distillation column 210 can be a conventional vacuum distillation column known to those of skill in the art. To achieve the advantages mentioned above, the multi-stage distillation column is operated such that the ratio of concentration of product alcohol in bottoms stream 214 is no more than about 90% of the concentration of feed 124, no more than about 50% of the concentration in feed 124, no more than about 10% of the concentration in feed 124, or, in embodiments no more than about 1% of the concentration in feed 124. In embodiments, multi-stage distillation column 210 is operated at a temperature range of from about 10° C. to about 65° C. and in a pressure range of from about 0.2 psia to any pressure under atmospheric pressure. In embodiments, multi-stage distillation column 210 is operated at a temperature range of from about 25° C. to about 60° C. and in a pressure range of from about 0.5 to about 3 psia (about 0.2 bars). In embodiments, the bottom temperature is about 46° C. and the top temperature is about 36° C.

As with the conventional vacuum flash tank described above, the flow rate to the multi-stage distillation column and the operation thereof are selected such that the titer of product alcohol in fermentation vessel 110 is maintained below a predetermined threshold level selected in consideration of the tolerance of the microorganism to the product alcohol. Consequently, in embodiments where bottoms stream 214 or a portion thereof is returned to fermentation vessel 110, it is advantageous to maintain a low concentration of product alcohol in the return stream. In embodiments, bottoms stream 214 contains less than about 10 g/L, less than about 7 g/L, less than about 5 g/L, less than about 2.5 g/L or less than about 1 g/L of the product alcohol.

In embodiments, the presence of carbon dioxide in the fermentation liquid feed to vacuum flash vessel 210 (which can be a vacuum flash tank or a distillation column, as discussed above) can complicate subsequent recovery of the alcohol, especially recovery by condensation. To reduce or substantially eliminate the amount of carbon dioxide present in the fermentation liquid feed to vessel 210, in embodiments presented herein, carbon dioxide can be pre-flashed from the fermentation liquid at a pressure intermediate between atmospheric pressure and the pressure of the flash at vessel 210. For example, in any of the processes described herein, fermentation liquid could be fed to a tank that is maintained at a partial vacuum which is insufficiently low pressure to cause the water and alcohol to boil but sufficient to pre-flash at least a portion of the carbon dioxide from the feed into a resultant vapor. For example, pre-flashing at 0.2 to 0.8 atmospheres pressure can necessitate further treatment of the resultant vapor. Such treatment can include compression and, in some embodiments, cooling of the resultant vapor including the carbon dioxide (and any associated water and alcohol also present) prior to discharge to the atmosphere. In other embodiments, carbon dioxide can be partially stripped from the fermentation liquid with a noncondensible gas such as air or nitrogen. For example, fermentation liquid can be countercurrently contacted with a noncondensible gas in a multistage vapor liquid contactor operating near atmospheric pressure. As an example, there can be used a three stage countercurrent column which accepts sterile compressed air at the bottom in a ratio of 0.2 to 5.0 mass units of air per mass units of carbon dioxide in the fermentation liquid, which is fed to the top of the column. The air-stripped carbon dioxide, and some quantity of alcohol and water can then be treated, for example scrubbed, to remove this alcohol before discharge to the atmosphere. Such removal of an amount of carbon dioxide according to the embodiments described here can reduce the complications that carbon dioxide can have on the downstream recovery of the alcohol vapor formed in vacuum flash vessel 210.

FIG. 9 illustrates an exemplary process 600 in which at least a portion of carbon dioxide is gas stripped from the fermentation feed upstream of flash vessel 210. Referring to FIG. 9, a stream 125 of mash, yeast and nutrients is introduced into fermentation vessel 110. A stream 122 including carbon dioxide is vented from fermentation vessel 110 to a water scrubber system (not shown). Stream 124 of fermentation liquid is heated in a heater 111 and introduced via a pump (not shown) into a multistage, countercurrent gas stripper 205. Stream 124 is contacted with a stream 220 of noncondensible gas, preferably an inert gas. In some embodiments, gas stream 220 is air or nitrogen. It should be apparent to one skilled in the art that by varying the number of stages in stripper 205 and the mass flow ratio of stripping gas 220 to fermentation liquid 124, it is possible to remove at least about 50% of the carbon dioxide in the fermentation liquid in some embodiments, and in other embodiments, at least about 55%, about 60%, about 65%, about 70%, about 75%, or about 80% of the carbon dioxide in the fermentation liquid. A stream 222 including stripping gas 220 and stripped carbon dioxide is vented from gas stripper 205. Stream 222 can be further treated, for example, by conveying stream 22 to a water scrubber system (not shown).

A stream 124′ of carbon dioxide-depleted fermentation liquid is passed through a valve 117 into a multi-compartment vessel 325, which includes vacuum flash vessel 210 and absorption column 310. In the embodiment of FIG. 9, flash vessel 210 is a vacuum flash tank that is a compartment of multi-compartment vessel 325. Vapor, rich in product alcohol, generated in the flash tank passes into a second compartment of multi-compartment vessel 325 and is exposed to cool absorbent liquid stream 324′ which causes substantial absorption of the vapor. Residual, unabsorbed vapor and inert gases are vented from multi-compartment vessel 325 via stream 328, which can then be conveyed through a compressor train (not shown in FIG. 9) in which vapor stream 328 passed through compressors with intercoolers and exhausted through a water scrubber system. For example, this compressor train can be similar to that shown and described below in Example 9 with reference to FIG. 8A. Liquid recycle stream 322 of absorption liquid is drawn from multi-compartment vessel 325, circulated at high rate through cooler 301 to remove the heat of absorption, and returned to multi-compartment vessel 325 as part of cool absorbent liquid stream 324′. A stream 323 of rich absorbent is drawn from the circulation loop of recycle stream 322 and regenerated via a regeneration process. Regenerated absorption liquid is returned via stream 432 to the circulation loop, cooled through cooler 301, and returned to multi-compartment vessel 325 as part of cool absorbent liquid stream 324′. The regeneration process (not shown in FIG. 9) can be similar that that shown and described below in Example 8 with reference to FIG. 7A.

Fermentation liquid 214, partially depleted in alcohol, is pumped from the vacuum flash tank of multi-compartment vessel 325. A portion 215 of fermentation liquid 214 can be advanced to additional product alcohol recovery systems for recovery of product alcohol, water and nonfermentables, and the remainder 214′ of fermentation liquid 214 can be returned to fermentation vessel to further ferment the sugars therein for alcohol production.

It should be apparent to one skilled in the art that a vacuum column can be substituted for the vacuum flash tank of multi-compartment vessel 325 in the embodiment of FIG. 9, without departing from the scope of the present invention. Also, it should be apparent that flash vessel 210 and absorption column 310 can be separate vessels connected by conduits, similar to process 100 of FIG. 1, rather being incorporated in multi-compartment vessel 325. Likewise, in embodiments, any of the processes provided herein, including process 100 of FIG. 1, can be alternatively configured such that flash vessel 210 and absorption column 310 are incorporated in the same vessel such as the multi-compartment vessel 325 described above.

Also, any of the processes provided herein can be operated in conjunction with other vaporization processes, such as those described in PCT International Publication No. WO2010/151832 A1.

Any of the processes provided herein can be operated and initiated at any time during a fermentation, and can be used to remove butanol or other product alcohol from a fermentation. In an embodiment, a process is initiated concurrently with initiation of a fermentation. In other embodiments, a process is initiated when the titer of product alcohol in the fermentation vessel is at least about 8 g/L, at least about 10 g/L, at least about 15 g/L, at least about 20 g/L, at least about 25 g/L, or at least about 30 g/L. In embodiments, processes described herein are repeated throughout the course of the fermentation. In embodiments, processes described herein are repeated such that the titer of product alcohol in the fermentation vessel is maintained at less than a preselected threshold.

EXAMPLES

Examples 1-4 were designed to determine the ability of certain absorption fluids to substantially reduce the volatility of carbon dioxide, isobutanol and water. The selected absorption fluids were monoethanolamine, methyl diethanol amine, and a mixture containing ethylene glycol and potassium carbonate. The reagents for these experiments are provided in Table 1. Example 5 is a comparative example without the absorption fluid.

A method known as the PTx method was used. Use of the PTx method is described in “Phase Equilibrium in Process Design,” Wiley-Interscience Publisher, 1970, written by Harold R. Null, pages 124 through 126, hereby incorporated by reference. In the PTx method, the total absolute pressure in a cell of known volume is measured at a constant temperature for various known loading compositions.

TABLE 1 Reagents Chemical name CAS # Purity Supplier Cat # page (Aldrich 2009- 2010) Methyl Diethanol Amine 105-59-9   >99% Aldrich 471828 1837 (MDEA ) 2-Methyl-1-propanol 78-83-1 99.50% Aldrich 53132-1L 1908 ( I-BuOH ) Potassium carbonate 584-08-7 >99.0% Aldrich 209619-100 g 2250 ( K₂CO₃ ) Ethylene Glycol 107-21-1   >99% Aldrich 102466-500 mL 1289 Monoethanolamine 141-43-5   >99% Aldrich 398136-500mL 1246

Carbon dioxide for examples 1-5 was Praxair product CD 4.0 IS-T with a specification of 99.99% carbon dioxide in the liquid phase (GTS/Welco, Allentown, Pa.).

Deionized water used in these experiments was from a stock supply. The conductivity of the deionized water was not believed to be relevant to the examples.

A schematic diagram of a static cell PTx apparatus 200 is shown in FIG. 2. The 72.73 cm³ flanged sapphire static cell 700 was immersed in a stirred 701, electrically heated Syltherm-800® constant temperature bath 702 with a RTD 703, an electricity supply 704, a heater 705 and an Eurotherm 2604 temperature controller 706, which controlled temperature to ±0.01° C. The static cell contained a magnetically driven mixer 710.

This mixer 710 included a 6-bladed Rhuston turbine constructed of Hastelloy C. Gas was entrained through a center whole of the magnet, via a hollowed carbon bushing, to the hollow shaft. Circulation of gas down the shaft to two right angle holes, from the vapor space into the turbine was provided to accelerate attainment of an equilibrium between the liquid and gas.

This static cell was leak proof. A port 715 was connected through a valve 716 to a vacuum pump 717 (Gardner Denver Thomas, Inc., Welch Vacuum Technology, Niles, Ill.; model 1376N); a port 725 was connected to an accurate pressure transducer 726 (Druck model # PDCR330; Keller America, Inc., Newport News, Va.); and a port 730 was connected to a feed pump 731 for carbon dioxide. The CO₂ feed pump 731 (Model 87-6-5; High Pressure Equipment Company, Erie Pa.) was sufficiently accurate to supply a volume known to ±0.001 cm³ at the specified pressure. Pressure in the CO₂ feed pump 731 was measured with a pressure transducer 732 (Paro Scientific, Inc. Model 740; Redmond, Wash.). The CO₂ feed pump 731 was also in a temperature controlled water bath 733 and could be isolated from the static cell with a valve 734. All compositions are specified on a component to total weight basis unless otherwise noted.

Example 1 Absorption Liquid MEA

The pressure composition relationship at a known temperature was measured with the described apparatus 200 as follows:

51.967 grams of a mixture of 6.99% isobutanol, 20.01% deionized water and 72.99% MEA were charged to static cell 700 and magnetically driven mixer 720 was started. The cell operating temperature was 44.42° C. and the liquid charge was 51.967 grams. The liquid mixture was degassed slowly by opening valve 716 connected to vacuum pump 717 until the cell pressure did not drop further. Valve 716 was then closed. The degas procedure was repeated until the cell pressure did not change with time when valve 716 to vacuum pump 717 was closed. The absence of leaks was verified by observing constant, below atmospheric pressure, in static cell 700 for at least 10 minutes. Cell 700 was heated to a targeted temperature with bath 702.

A measured volume of carbon dioxide at known pressure and temperature was introduced to cell 700 and the cell contents were agitated until the cell pressure remained constant. This cell pressure was noted. Additional carbon dioxide of known volume was added and a constant cell pressure was again noted. This step was repeated until a targeted quantity of carbon dioxide had been added. For the purpose of data analysis, the volume of carbon dioxide at known temperature and pressure was converted to mass using the reference, NIST 14, Thermodynamics and Transport Properties of Fluids, NIST Standard Reference Database 14, Version 4. Results are given in Table 2.

TABLE 2 Effect of MEA on vapor pressure Grams of CO₂ added to cell Vapor pressure in cell - psia 0 0.676 0.4912 0.735 0.9908 0.778 1.4971 0.826 1.9656 0.871 2.4939 0.922 3.1277 0.977 3.7217 1.024 4.3925 1.083 5.0284 1.137

Example 2 Absorption liquid MEA

The procedures of Example 1 were repeated except the cell operating temperature was 44.46° C., the liquid composition was 7.24% Isobutanol, 20.57% water, 72.2% Monoethanolamine and the liquid charge was 49.925 grams. Results are given in Table 3.

TABLE 3 Effect of MEA on vapor pressure Grams of CO2 added to cell Vapor pressure in cell - psia 0 0.684 0.0739 0.694 0.1577 0.705 0.2798 0.716 0.4121 0.724 0.5362 0.734 0.6657 0.742 0.8186 0.752 0.9679 0.761 1.1521 0.772

Example 3 Absorption Liquid MDEA

The procedures of Example 1 were repeated except the cell operating temperature was 44.45° C., the liquid composition was 4.99% Isobutanol, 12.01% water, and 83% methyldiethanolamine, and the liquid charge was 52.087 grams. Results are given in Table 4.

TABLE 4 Effect of MDEA on vapor pressure Grams of CO2 added to cell Vapor pressure in cell - psia 0 0.654 0.0833 0.990 0.1678 1.5 0.3001 2.428 0.3966 3.153 0.5009 3.97 0.6058 4.812 0.7058 5.643 0.8164 6.579 0.9220 7.501

Example 4 Ethylene Glycol and Potassium Carbonate Mixture as Absorption Liquid

The procedures of Example 1 were repeated except the cell operating temperature was 44.52° C., the liquid composition was 6.86% Isobutanol, 18.1% water, 9.04% potassium carbonate, and 66.01% ethylene glycol, and the liquid charge was 56.297 grams

TABLE 5 Effect of ethylene glycol and potassium carbonate mixture on vapor pressure Grams of CO2 added to cell Vapor pressure in cell - psia 0 0.886 0.08182 0.892 0.16689 0.898 0.30605 0.913 0.55314 0.953 0.80033 1.030 1.01325 1.163 1.39296 5.888 1.43120 10.145 1.46580 14.544

Comparative Example 5 Absence of Absorption Liquid

A control experiment was also performed in which CO₂ was added into deionized water using the same cell. The procedures of Example 1 were repeated except the cell operating temperature was 49.4° C., the liquid composition was 100% deionized water, and the liquid charge was 53.919 grams.

TABLE 6 Vapor pressure in the absence of absorption liquid Grams of CO2 added to cell Vapor pressure in cell - psia 0 1.74 0.01689 5.00 0.12823 26.22 0.22952 45.71 0.33327 65.80 0.43932 86.38 0.53909 105.85 0.64063 125.77 0.74679 146.77 0.84640 166.51 0.97062 191.26

The vapor pressure of the absorbent solutions used in Examples 1-4 were less than the vapor pressure of water alone from Example 5. Addition of even small amounts of carbon dioxide to water in the absence of absorption liquid, for example 0.01223 grams in 53.919 grams of water, resulted in a substantial increase in the static cell pressure as can be seen in Example 5. Thus, an absorber containing water only, operating at near 45° C. and less than 2 psia, would condense only a small amount of carbon dioxide per unit of water absorption liquid. Some combination of refrigerated condensation and a compressor would be required to purge carbon dioxide from a vacuum flash with only water as an absorption liquid. An absorber containing ethylene glycol and potassium carbonate, or methyl diethanolamine absorption liquids, at concentrations above 70% would condense more carbon dioxide per unit of absorption liquid than the water would at about 45° C. and 2 psia. An absorbent containing monoethanolamine at a concentration of 70% to 75% would condense even more carbon dioxide per unit of scrubbing solution at near 45° C. and 2 psia and would require less absorbent per unit of carbon dioxide than the other Examples.

Example 6 Absorption and Desorption of CO₂: Absorption Liquid MEA

The purpose of this example was to demonstrate carbon dioxide absorption and then desorption in one of the absorbent solutions, monoethanolamine.

The example was developed using a 1.8 L HC60 Mettler RC1 agitated and jacketed calorimeter (Mettler-Toledo Mid Temp, Mettler-Toledo Inc., Columbus, Ohio) outfitted with a Mettler-Toledo REACT IR model 1000 In-Line FTIR using a DiComp, Diamond ATR Probe (Mettler-Toledo). The Diamond ATR probe was inserted into the RC 1 reactor and sealed with a Swagelok fitting to form a pressure tight seal.

The pressure in the calorimeter was measured and recorded by an integrated Dynisco pressure transducer and RC press data recorder and control system. The weight of the CO₂ cylinder, the reactor content temperature, the jacket temperature and the reactor pressures were likewise measured by components of the RC1 and recorded by the RC1 software. The weight of the CO₂ was determined to plus or minus 0.5 grams by displacement from a 2 A cylinder.

Materials used in the calibration and absorption/desorption experiment described below were monoethanolamine, CAS 141-43-5 (catalog no. 398136, purity >99%; Sigma-Aldrich Corp., St. Louis, Mo.); 2-methylpropan-1-ol, CAS No 78-83-1 (Sigma-Aldrich catalog no. 53132-1L of 99.50% purity); and CO₂, 99.8% purity (Airgas East, Salem, N.H.; specification CGA G-6.2 Grade H).

Calibrating the FTIR

750.0 g of a solution containing 547.5 g of monoethanolamine, 52.5 g of 2-methylpropan-1-ol and 150.0 g of deionized water were added to the RC1 calorimeter and heated to 45° C. while agitating at 600 rpm. The reaction solution was purged with 99.9999% pure nitrogen gas subsurface through a dip tube for 2 hours at a rate of 200 sccm. Nitrogen flow was stopped and the vessel was then pumped down to a pressure of 0.05 bar using a Welch model 1402 vacuum pump (Gardner Denver Thomas, Inc., Welch Vacuum Technology, Niles, Ill.). The degassed fluid in the evacuated and sealed reactor was then exposed to CO₂ at 0.10 bar and 45° C. The CO₂ was introduced into the reactor beneath the surface using a ⅛th inch diameter stainless steel dip tube. The CO₂ was added in 5 g aliquots until 35 g of CO₂ were absorbed. The FTIR spectra were allowed to line out before additional CO₂ was added at each 5 g increment.

Mid-IR spectra were collected every 2 minutes during the experiments. The absorption of CO₂ into monoethanolamine forms a bicarbonate complex which has numerous IR absorbances (see FIG. 3). A band near 1309 cm⁻¹ was selected to follow the course of this experiment. A univariate approach was used to follow the 1309 cm⁻¹ peak with baselines drawn between 1341 cm⁻¹ and 1264 cm⁻¹. Absorbances to the two point baseline were used to create both the bicarbonate calibration plot and the temperature dependence plot. The CO₂ absorbed vs. peak height at 1309 cm⁻¹ is shown in FIG. 4.

The solution with the absorbed CO₂ was heated in a sealed vessel and the peak height monitored throughout. A temperature vs. peak height calibration was generated and is shown in FIG. 5.

After the above calibration, an experiment was conducted to demonstrate absorption and desorption. 750.0 g of a solution containing 547.5 g of monoethanolamine, 52.5 g of 2-methylpropan-1-ol and 150.0 g of deionized water were added to the RC1 calorimeter at 45° C. while agitating at 800 rpm. The reaction solution was purged with 99.9999% pure nitrogen gas subsurface through a ¼ inch outside diameter, 0.18 ID dip tube for 2 hours at a rate of 200 sccm. The vessel was then pumped down to a pressure of 0.05 bar using a Welch model 1402 vacuum pump. The degassed fluid was exposed to carbon dioxide at 45° C. The CO₂ was introduced into the reactor beneath the surface using the ¼ inch outside diameter stainless steel dip tube. The CO₂ was taken up at a nearly constant rate of 6 g/min for nearly 6 minutes until a total of approximately 35 g of CO₂ was taken up into the reactor. The freeboard in the reactor was estimated to be about 0.75 liters and so the amount of CO₂ in the vapor space under these conditions was calculated to be no more than 0.1 g so that approximately 34.9 g of the 35 g was absorbed into the liquid solution. The pressure of the reactor was 70 mmHg after the CO₂ was added.

The reaction mass was heated to 150° C. at 1° C./min. As the temperature reached 118° C. the pressure was approximately 1.1 bar. A vent line was opened and vapor released from the reaction vessel into a vertically mounted condenser cooled with brine at −15° C. The bottom of condenser contacted a separatory funnel, the bottom outlet of which was opened back to the vessel so as to maintain a constant temperature once the final desired reaction temperature was achieved by adjusting the boiling point of the solution in the reactor. In this way CO₂ liberated from the monoethanolamine solution was vented from the process while the condensed liquids were returned. The vent line from the top of the vertically mounted condenser was attached to a bubbler and the formation of bubbles in the bubbler was an indication that CO₂ was being liberated from the reaction vessel. In addition, the in-line FTIR monitored the 1309 cm⁻¹ wavenumber peak indicative of the formation of a bicarbonate species or complex owing to the reaction of CO₂ and monoethanolamine. The FTIR peak profile indicated complete desorption of the CO₂ from the monoethanolamine peak in about 2.5 hours with over 60% of the desorbed CO₂ regenerated in about ½ hour. After 2.5 hours the 1309 cm⁻¹ peak returned to its original base line value indicating all of the CO₂ had desorbed from the monoethanolamine solution. The bubbler also showed no signs of gas evolution after 2.5 hours.

This example demonstrates that an absorbent solution can be utilized to absorb carbon dioxide and then regenerated.

Example 7 ASPEN Model: Absorption Liquid Comprising Ethylene Glycol and Potassium Carbonate

Processes described herein can be demonstrated using a computational model of the process. As described in U.S. Pat. No. 7,666,282, process modeling is an established methodology used by engineers to simulate complex chemical processes (and is incorporated herein by reference). The commercial modeling software Aspen Plus® (Aspentech, Burlington, Mass. 01803) was used in conjunction with physical property databases, such as DIPPR, available from the American Institute of Chemical Engineers, Inc., of New York, N.Y., to develop an ASPEN model of an integrated butanol fermentation, purification and water management process.

Model inputs are defined in Table 7. A subset of this model illustrating the invention is best understood by reference to FIG. 6A which illustrates a flow diagram of a model process 300. Streams and outputs resulting from process 300 described are given in Tables 8A and 8B provided as FIGS. 6B and 6C, respectively. Batch fermentation was modeled as a steady state, continuous process using average flow rates.

With reference to FIG. 6A, mash stream 23MASH (123), and biocatalyst stream YEAST (121) are introduced to fermentation vessel 110. A vapor stream 112VAP (122), containing carbon dioxide, water and butanol, is vented from the fermentation vessel 110 and directed to a butanol recovery scrubber (not shown). Beer stream 114BEER (114), heated to 31.4° C., is passed through a throttling valve 117, and is admitted into vacuum flash vessel 210 (which is a flash tank in this Example) as stream 113BEER (124). Flash tank 210 is at 0.1 bar which results in a portion of the beer flashing and a drop in temperature to 28° C. The flow rate and temperature of stream 113BEER (124) are selected to assure that the concentration of butanol in fermentation vessel 110 did not exceed 0.025 weight fraction. In this example, the ratio of butanol in a flashed beer stream 115BEER (214) compared to stream 113BEER (124) is 0.85.

Flashed beer stream 115BEER (214) is split into (i) a stream 24BEER (119), which simulates an average flow rate of a purge stream of nonfermentables and byproducts to additional butanol recovery systems (not shown) for butanol recovery, and (ii) a recycle stream 116REC (116) of yeast and unfermented sugars that is returned back to fermentation vessel 110.

A Stream 67VENT (212), which is vapor from flash tank 210 enriched to 31.8 weight percent butanol and with a dewpoint of 28° C., is directed to vacuum absorption column 310 in which nearly all vapors are absorbed while operating with a bottoms temperature of 41.2° C. A stream VENT (328) including noncondensibles, and having near zero mass flow rate (in part representing air leaks into the vacuum equipment), is compressed and discharged to atmosphere through a water scrubber (not shown).

Vacuum absorption column 310 is supplied with two flows of absorbent, absorption liquid streams RICH1B (324) and LEAN (320). In this Example, the absorbent is ethylene glycol containing potassium carbonate and bicarbonate. Stream RICH1B (324) is absorbent re-circulated from the bottom of absorption column 310 after sufficient cooling to remove most or all of the heat of absorption. Stream LEAN (320) is absorbent returned from the regeneration process, described below, in sufficient quantity for assuring nearly complete absorption of carbon dioxide, butanol and water. The combined bottoms stream RICH (322′) is divided to supply stream RICH1B (324) and a stream RICH3 (323), which is diluted absorbent that is heated and directed to an absorbent regeneration column (serving as stripping column 410).

Regeneration column 410 is supplied heat at the base by indirect exchange with steam in sufficient quantity to vaporize almost all carbon dioxide and butanol, as well as sufficient water, to maintain a steady state composition. A column bottoms stream LEANT (432) is cooled, including in part by heat rejection to stream RICH3 (323) via a heat integration, and returned to absorption column 310 as stream LEAN (320).

A stream VAPOR (440) exits regeneration column 410 at one atmosphere and is partially condensed and separated (at vapor-liquid separator 505) to produce a stream COLVENT (442), which is a carbon dioxide purge that is discharged through a water scrubber (not shown). Condensate stream CONDENSE (444) is pumped (pump not shown) to condensate decanter vessel 510, combined with additional streams not described herein, and decanted. Decanter 510 generates an organic upper layer BUOH (548) which is sent to a butanol column (not shown) for purification and, ultimately, commercial sales. A lower aqueous layer AQUEOUS (546) is returned as reflux to regeneration column 410. A liquid phase side draw is taken from regeneration column 410 between the reflux addition point and the feed addition point. This side draw stream WATEROUT (450) is pumped to the beer column (not shown) for further recovery of butanol.

TABLE 7 Model Inputs for Example 7 Input Value Units Production 50 MM gal per year Backset 15 % Corn Feed Water Content 15 % Corn Composition (dry) STARCH 70 % C5POLY 5.2 % C6POLY 3 % PROTEIN 9.8 % OIL 4 % NFDS 8 % Waste from Milling 0.3 % Misc Feeds to Mash CIP 2256 kg/hr Enzyme 31.47 kg/hr CA 53.6 kg/hr Ammonia 89.8 kg/hr Mash Cooking inlet mash temperature 190 deg F. intermediate mash temperature approach 18 deg F. to maximum temp Maximum mash temperature 230 deg F. Saccharification enzyme feed 45.6 kg/hr acid feed 21.1 kg/hr Starch Conversion 99 % Saccharifier Temp 140 deg F. Saccharifier Pres 40 psia Initial Cooldown approach to 18 deg F. fermentation vessel temperature Fermentation Vessel yeast feed 8.5 kg/hr inlet temperature 90 deg F. Glucose Conversion 100 % NFDS Conversion Fermentation vessel Temp 90 deg F. Fermentation vessel Pres 16 psia BuOH Titer 25 g/L Flash tank pressure 0.7 psia Flash tank liquid recirculation 5061 t/hr CO2 Degasser Degasser pressure 16 psia Degasser condenser temperature 100 deg F. dT between degas temp and Beer Col 10 deg C. bottoms cooler exit Beer Column # of stages 12 column pressures Top 20 psia Bottom 21.5 psia feed stage locations degassed liquid stage 4 Condensate stage 1 Aqueous reflux stage 1 Butanol mass recovery 99.65 % BuOH Column # of stages 10 column pressures Top 14.5 psia Bottom 15.2 psia feed stage locations Organic Reflux / Feed Stage 1 Water in Bottom Product 0.01 % BuOH Product Cooler exit temp 104 deg F. exit pres 18.5 psia Scrubber # of stages 7 Pressure 15 psia Centrifuge solids/total flow in centrifuge tails 0.287 Distiller's Dried Grains with Solubles (DDGS) dryer water concentration in DDGS product 9 % Evaporators water concentration exit 4^(th) evaporator 60 % 1st evaporator pressure 5.37 psia 2nd evaporator temperature 63.7 deg C. 3rd evaporator temperature 53.2 deg C.

This Example demonstrates that the absorption temperature is 13° C. higher than the dew point of the vapor stream. Comparing stream 67VENT (212) to stream VENT (328) shows that more than 99% of the vapor stream including carbon dioxide is absorbed into the absorption. Furthermore, the Example demonstrates that the absorption liquid can be regenerated using processes described herein.

Example 8 ASPEN Model: Vaporization in Multi-Stage Distillation Column and Absorption Liquid Comprising Ethylene Glycol

An ASPEN model of an integrated butanol fermentation, purification and water management process was developed. The model inputs are given in Table 9. The model is described with reference to FIG. 7A, which illustrates a flow diagram of a model process 400. Streams and outputs resulting from process 400 described are given in Tables 10A and 10B provided as FIGS. 7B and 7C, respectively. Batch fermentation is modeled in this example as a steady state, continuous process using average flow rates.

With reference to FIG. 7A, mash stream 23MASH (123), and biocatalyst stream YEAST (121) are introduced to fermentation vessel 110. A vapor stream 68CO2 (122′), containing carbon dioxide, water and butanol, is vented from fermentation vessel 110 and directed to a butanol recovery scrubber (not shown). Beer containing 25 grams per liter butanol is passed through an atmospheric disengagement tank 112 in which vapors from the beer are vented via a stream 68CO2 (122′), which is a stream combining the vented vapors from fermentation vessel 110 and disengagement tank 112. The circulated beer is then heated to form stream 26BEER (124), which is introduced into a vacuum flash multi-stage distillation column 215 (corresponding to vacuum flash vessel 210 of the process of FIG. 1). The pressure at the top of column 215 is at 0.07 atmospheres, and the butanol concentration in the gas stream is 34.5% by mass. Column 215 is indirectly heated. The number of stages of column 215, the heat input to column 215 and the flow rate of stream 26BEER (124) are selected to assure that the concentration of butanol in fermentation vessel 110 does not exceed the preselected threshold 0.025 weight fraction. Bottoms from vacuum flash column 215 containing 0.3 grams per liter butanol is split into (i) a stream 28RCY (128) that is returned to fermentation vessel 110 to ferment additional sugar to butanol, and (ii) a stream 29BEER (129) that is directed to a water recycle and Distiller's Dried Grains with Solubles (DDGS) production process (not shown). With the methods described herein, compounds that may be contaminating to DDGS are isolated from such co-product streams as opposed to other product removal processes, and therefore may provide additional benefit to fermentations comprising the product recovery methods described herein.

A vapor stream 30BOV (212) enriched to 34.5 weight percent butanol is directed from flash column 215 to vacuum absorption column 310. In absorption column 310, approximately 67% of the water plus butanol is absorbed from vapor stream 30BOV (212), but almost none of the carbon dioxide is absorbed. A vapor stream 328 from absorption column 310 is cooled, and a condensate stream 32COND (844 a) is separated (at vapor-liquid separator 805) from residual vapors. From separator 805, a residual vapor stream 34VAP (342) is compressed, cooled again, and a condensate stream 38COND (844 b) is separated (at vapor-liquid separator 806) from residual vapors which form a stream 40VAP (344) that is directed to a water scrubber (not shown).

Vacuum absorption column 310 is supplied with two flows of absorbent, absorption liquid streams 324 and 320. In this Example, the absorbent is ethylene glycol (glycol) without potassium carbonate or other base. Stream 324 is absorption liquid re-circulated from the bottom of absorption column 310 after sufficient cooling to remove most or all of the heat of absorption. Stream 320 is absorption liquid returned from the regeneration process, described below. The combined bottoms stream 322′ is divided to supply stream 324 and stream 323. Stream 323 is diluted absorption liquid (or solution rich with solutes) which is heated and directed to absorption regeneration column 410.

Absorption regeneration column 410 is supplied heat at the base by indirect exchange with steam in sufficient quantity to vaporize butanol and water to maintain a steady state composition. Column bottoms stream 432 is cooled, including in part by heat rejection to stream 323 via a heat integration, and returned as stream 320 to absorption column 310.

Vapor stream 440 exits regeneration column 410 at one atmosphere and is combined with other vapors and partially condensed and separated (at vapor-liquid separator 505) to produce stream COLVENT (442), which is a carbon dioxide purge that is discharged through a water scrubber (not shown). Condensate stream CONDENSE (444) is pumped (pump not shown) to condensate decanter vessel 510, combined with additional streams not described herein, and decanted. Decanter 510 generates an organic upper layer 470RG (548) which is sent to a butanol column (not shown) for purification and, ultimately, commercial sales. A lower aqueous layer 48AQ (546) is in part returned as reflux (not shown) to flash column 215 and in part used as reflux (not shown) for regeneration column 410.

TABLE 9 Model Inputs for Example 8 Input Value Units Production 50 MM gal per year Backset 15 % Corn Feed Water Content 15 % Corn Composition (dry) STARCH 70 % C5POLY 5.2 % C6POLY 3 % PROTEIN 9.8 % OIL 4 % NFDS 8 % Waste from Milling 0.3 % Misc Feeds to Mash CIP 2256 kg/hr Enzyme 31.47 kg/hr CA 53.6 kg/hr Ammonia 89.8 kg/hr Mash Cooking inlet mash temperature 190 Deg F. intermediate mash temperature 18 Deg F. approach to maximum temp Maximum mash temperature 230 Deg F. Saccharification enzyme feed 45.6 kg/hr acid feed 21.1 kg/hr Starch Conversion 99 % Saccharifier Temp 140 Deg F. Saccharifier Pres 40 psia Initial Cooldown approach to 18 Deg F. fermentation vessel temperature Fermentation vessel yeast feed 8.5 kg/hr inlet temperature 90 Deg F. Glucose Conversion 100 % NFDS Conversion Fermentation vessel Temp 90 Deg F. Fermentation vessel Pres 16 psia BuOH Titer 25 g/L Two Stage Compressor/Condenser First stage pressure 4 psia Second stage pressure 16 psia Vacuum condenser temperature 30 Deg C. Beer Column # of stages 6 column pressures Top 1 psia Top condenser temperature 30 deg C. feed stage locations stream from fermentation vessel Stage 1 aqueous reflux Stage 1 Butanol mass recovery 99 % EG Absorber # of stages 5 Top P 0.8 psia EG Feed Stage 1 Beer vapor feed Stage 5 BUOH Regeneration Col # of stages 15 Top P 1 atm Reflux Aqueous phase from decanter stage 1 Bottom IBA spec 100 ppm BuOH Column # of stages 8 column pressures Top 20 psia Bottom 22 psia feed stage locations Organic Reflux/Feed Stage 1 BuOH in bottoms 99.55 % BuOH Product Cooler exit temp 104 Deg F. exit pres 18.5 psia Scrubber # of stages 6 Pressure 15 psia Centrifuge solids/total flow in centrifuge tails 0.287 DDGS dryer water concentration in DDGS 9 % product Evaporators water concentration exit 4th 45 % evaporator 1st evaporator pressure 20 psia 2nd evaporator temperature 99 Deg C. 3rd evaporator temperature 88 Deg C. 4th evaporator temperature 78 Deg C.

This Example shows that use of a multi-stage distillation column can reduce the amount of carbon dioxide removed with butanol while maintaining the butanol concentration at or below a preselected threshold of 2.5 mass percent in the fermentation tank. Also, the multi-stage distillation column is operated such that the butanol concentration in the column feed is more than 80 times greater than that in the bottoms stream returned to the fermentation vessel. Furthermore, use of an absorption liquid, here, ethylene glycol is used without a base, allows absorption of approximately 65% by mass of the sub-atmospheric vapor at an initial condensation temperature of 40.9° C., which is higher than the initial condensation temperature of the sub-atmospheric vapor stream in the absence of an absorption liquid, that is, 37.7° C.

Example 9 Multi-Stage Distillation Column Example—No Absorption Step

An ASPEN model of an integrated butanol fermentation, purification and water management process 500 was developed and is described with reference to FIG. 8A. All flow rates were modeled as time averages even though they may be non-continuous. Model inputs are given in Table 11, and results are given in Tables 12A and 12B provided as FIGS. 8B and 8C, respectively.

With reference to FIG. 8A, mash and nutrients stream 23MASH (123), and biocatalyst YEAST stream (121) are introduced to fermentation vessel 110. Vapor stream 68CO2 (122′) containing carbon dioxide, water and butanol are vented from fermentation vessel 110 and directed to a butanol recovery scrubber (not shown). Beer is circulated from 110 fermentation vessel to a vacuum beer column 120 (via atmospheric disengagement tank 112) at sufficient rates to assure that the butanol concentration in the beer does not exceed a preselected threshold target, in this case 2.5% by weight. In atmospheric disengagement tank 112), vapors from the beer are vented and combined with vapor stream 68CO2 (122′). The circulated beer is then heated to form stream 26BEER (124), which is introduced into multistage, sub-atmospheric beer column 120. The feed point and the number of stages can be optimized by those familiar with the state of the art of beer column design. In this model the number of theoretical stages in beer column 120 is 6 and the feed is to stage #1. Sufficient heat is added at the bottom of beer column 120 in the form of low pressure steam to reduce the butanol content of the beer by more than 98%. In this example the pressure at the top of column 120 is 1 psia.

A beer column bottoms stream 27BOT (127) is substantially stripped of butanol in beer column 120, and a portion of stream 27BOT (127) (about 70%) is returned to fermentation vessel 110 as recycle stream 28RCY (128) for further conversion of carbohydrates to butanol. The remainder of the stripped beer, stream 29BEER (129), is sent to a DDGS system (not shown) of the types known in the art as may be necessary to control accumulation of suspended solids and other impurities.

A vapor stream 30BOV (130) from beer column 120, enriched in butanol, is cooled, and a liquid condensate stream 32COND (132) and a vapor stream 34VAP (134) are separated in a vacuum vapor-liquid separator 905. The remaining vapor is conveyed through a compressor train, in which it is compressed, cooled and separated two times (at respective compressor 906, vapor-liquid separator 915, compressor 907, and vapor-liquid separator 925) to produce additional condensate streams 37COND (137) and 43COND (143) from separators 915 and 925. A residual vapor stream 40 VAP (140) from this compressor train is above atmospheric pressure and is routed to a water scrubber (not shown) before discharge to the atmosphere. Condensate streams 32COND (132), 37COND (137) and 43COND (143) are combined with additional streams not described herein, and decanted in a decanter 515. A water rich lower phase 508 from decanter 515 is returned to beer column 120. An organic rich upper phase 506 from decanter 515 is sent to a butanol recovery column (not shown) for purification and, ultimately, commercial sales.

TABLE 11 Model Inputs for Example 9 Input Value Units Production 50 MM gal per year Backset 15 % Corn Feed Water Content 15 % Corn Composition (dry) STARCH 70 % C5POLY 5.2 % C6POLY 3 % PROTEIN 9.8 % OIL 4 % NFDS 8 % Waste from Milling 0.3 % Misc Feeds to Mash CIP 2256 kg/hr Enzyme 31.47 kg/hr CA 53.6 kg/hr Ammonia 89.8 kg/hr Mash Cooking inlet mash temperature 190 deg F. intermediate mash temperature 18 deg F. approach to maximum temp Maximum mash temperature 230 deg F. Saccharification enzyme feed 45.6 kg/hr acid feed 21.1 kg/hr Starch Conversion 99 % Saccharifier Temp 140 deg F. Saccharifier Pres 40 psia Initial Cooldown approach to 18 deg F. fermentation vessel temperature Fermentation vessel yeast feed 8.5 kg/hr inlet temperature 90 deg F. Glucose Conversion 100 % NFDS Conversion Fermentation vessel Temp 90 deg F. Fermentation vessel Pres 16 psia BuOH Titer 25 g/L Two Stage Compressor/Condenser First stage pressure 4 psia Second stage pressure 16 psia Vacuum condenser temperature 30 deg C. Beer Column # of stages 6 column pressures Top 1 psia Top condenser temperature 30 deg C. feed stage locations stream from fermentation vessel stage 1 aqueous reflux stage 1 Butanol mass recovery 99 % BuOH Column # of stages 8 column pressures Top 20 psia Bottom 22 psia feed stage locations Organic Reflux / Feed Stage 1 BuOH in bottoms 99.55 % BuOH Product Cooler exit temp 104 deg F. exit pres 18.5 psia Scrubber # of stages 6 Pressure 15 psia Centrifuge solids/total flow in centrifuge 0.287 tails DDGS dryer water concentration in DDGS 9 % product Evaporators water concentration exit 4th 45 % evaporator 1st evaporator pressure 20 psia 2nd evaporator temperature 99 deg C. 3rd evaporator temperature 88 deg C. 4th evaporator temperature 78 deg C.

This Example demonstrates that efficient stripping of butanol in the beer column permits a flow rate allowing 20002 kg/h of CO₂ to vent from fermentation vessel 110 and optional atmospheric flash tank (i.e., atmospheric disengagement tank 112) compared to only 961 kg/h through sub-atmospheric beer column 120 and compressor train. Consequently, the compressor is smaller and will require less energy than if a higher fraction of the CO₂ were vented from sub-atmospheric beer column 120. Also, the multi-stage distillation beer column 120 is operated such that the butanol mass in the bottoms stream 127 is about 1% of the butanol mass in the feed stream 124.

Example 10 Air Stripping before Vacuum Flash

An ASPEN model of an integrated butanol fermentation, purification and water management process 700 was developed and is described with reference to FIG. 10A. All flow rates were modeled as time averages even though they may be non-continuous. Model inputs are given in Table 13, and results are given in Tables 13A and 13B provided as FIGS. 10B and 10C, respectively.

With reference to FIG. 10A, mash and nutrients stream 125, and biocatalyst (not shown) are introduced to fermentation vessel 110. A vapor stream 122″ containing carbon dioxide, water and butanol are vented from fermentation vessel 110 and directed to a butanol recovery scrubber (not shown). Beer is circulated from 110 fermentation vessel. A portion, 415, is directed to a beer column (not shown) to purge non-fermentables. A portion, 124, is directed to an air stripper 210 at sufficient rates to assure that the butanol concentration in the beer does not exceed a preselected threshold target, in this case 2.5% by weight. Carbon dioxide is stripped from the beer in a three stage column provided 2308 kg/h of air. The stripping gas flow rate and the number of stages can be optimized by those familiar with the stripping column design. Sufficient heat is added by heater 360 to maintain the temperature of flash tank 325 (described below) at 32C. The beer is passed through throttling valve 117 into the lower compartment of vessel 325 where it is allowed to flash at a pressure of 0.05 atm, causing the vaporization of butanol, carbon dioxide and water. These vapors, enriched in butanol, pass into compartment 310′ of vessel 325 were they are partially condensed at 20C. Condensate is removed from 310′ and pumped through a cooler 401 and returned by stream 424′ to maintain the condensation temperature. A portion of the condensate, 323′, is removed from the circulation loop and further processed to produce product butanol and water suitable for recycle in facilities not shown. The remaining vapor, stream 428 is conveyed through a compressor train, in which it is compressed, cooled and separated two times as described in Example 8.

Beer not flashed in the flash tank is pumped (not shown) by stream 414 to return nutrients to the fermentation vessel for further fermentation.

TABLE 12 Model Inputs for Example 10 Input Value Units Production 40 MM gal per year Backset 15 % Corn Feed Water Content 15 % Corn Composition (dry) STARCH 70 % C5POLY 5.2 % C6POLY 3 % PROTEIN 9.8 % OIL 4 % NFDS 8 % Waste from Milling 0.3 % Fermentation vessel yeast feed 8.5 kg/hr inlet temperature 90 deg F. Glucose Conversion 100 % NFDS Conversion Fermentation vessel Temp 90 deg F. Fermentation vessel Pres 16 psia BuOH Titer 25 g/L Air Stripper Stages 3 Air flow rate 2308 Kg/h Flash Tank Pressure 0.05 Atm Inlet Temperature 31.8 deg C. Condenser temperature 20 deg C.

This Example demonstrates that air stripping of beer after the fermentation vessel and prior to flashing will reduce the CO₂ content in the vapor from the flash. Consequently, the vapors from the flash may be more completely condensed at temperatures on the order of 20 C.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

All publications, patents and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains, and are herein incorporated by reference to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference. 

1-27. (canceled)
 28. A method for removing a product alcohol from a fermentation liquid, comprising: (a) at least partially vaporizing a fermentation liquid wherein a vapor stream is produced, the fermentation liquid and the vapor stream each comprising an amount of water, butanol, and optionally CO₂; and (b) contacting the vapor stream with an absorption liquid under vacuum conditions wherein at least a portion of the vapor stream is absorbed into the absorption liquid to form an absorption liquid phase, wherein the portion of the vapor stream that is absorbed includes an amount of each of the water and the butanol, and optionally CO₂, and wherein temperature at the onset of the absorption of the vapor stream into the absorption liquid is greater than temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid.
 29. The method of claim 28, wherein the absorption liquid comprises a water soluble organic molecule with a boiling point at least about 30° C. greater than the boiling point of water at atmospheric pressure.
 30. The method of claim 28, wherein the organic molecule is an amine selected from the group consisting of monoethanolamine (MEA), 2-amino 2-methyl propanol (AMP), and methyldiethanolamine (MDEA).
 31. The method of claim 28, wherein the absorption liquid comprises ethylene glycol.
 32. The method of claim 28, wherein the (a) vaporizing comprises: (i) removing the fermentation liquid feed from a fermentation vessel; (ii) supplying the fermentation liquid feed to a multi-stage distillation column at a flow rate; (iii) distilling the fermentation liquid feed to produce the vapor stream enriched in butanol and a bottoms stream depleted in the product alcohol, wherein the distilling occurs under a pressure sufficiently below atmospheric to allow for the vapor stream to be produced at a temperature no greater than about 45° C.; and (iv) optionally, returning any portion of the bottoms stream to the fermentation vessel, wherein the concentration of the product alcohol in the bottoms stream is not more than about 90% of the concentration of the product alcohol in the fermentation liquid feed.
 33. The method of claim 32, wherein the fermentation liquid comprises CO₂, wherein the (a) vaporizing step further comprises, prior to the (ii) supplying step, of gas stripping a portion of the CO₂ from the fermentation liquid feed and vaporizing a portion of the CO₂ from the fermentation liquid feed.
 34. (canceled)
 35. A method for maintaining the titer of product alcohol in a fermentation vessel below a preselected threshold, the method comprising: (a) removing from a fermentation vessel a fermentation liquid feed stream produced from a fermentation in the fermentation vessel, the fermentation liquid feed stream comprising product alcohol, water, and optionally CO₂; (b) supplying the fermentation liquid feed stream to a single stage flash tank or a multi-stage distillation column; (c) at least partially vaporizing under vacuum conditions the fermentation liquid feed stream in the single stage flash tank or the multi-stage distillation column to produce a vapor stream enriched in product alcohol and a bottoms stream depleted in product alcohol; (d) optionally returning any portion of the bottoms stream to the fermentation vessel; and (e) contacting the vapor stream with an absorption liquid under vacuum conditions; wherein at least a portion of the vapor stream is absorbed into the absorption liquid, wherein the absorption liquid comprises a water soluble organic molecule different from the product alcohol.
 36. The method of claim 35, wherein the temperature at the onset of the absorption of the vapor stream into the absorption liquid is greater than the temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid.
 37. The method of claim 36, wherein the concentration of product alcohol in the bottoms stream is less than about 90% of the concentration of product alcohol in the fermentation liquid feed stream.
 38. The method of claim 37, wherein the concentration of product alcohol in the bottoms stream is less than about 10% of the concentration of product alcohol in the fermentation liquid feed stream.
 39. The method of claim 35, wherein the organic molecule is an amine.
 40. The method of claim 35, wherein the organic molecule is ethylene glycol.
 41. The method of claim 35, wherein the concentration of product alcohol of the bottoms stream is less than about 2.5 g/L.
 42. The method of claim 35, wherein the fermentation liquid feed stream comprises CO₂.
 43. The method of claim 35, wherein the method is initiated when the product alcohol in the fermentation vessel reaches about 10 g/L.
 44. The method of claim 35, wherein the method is initiated concurrently with initiation of the fermentation producing the fermentation liquid feed stream.
 45. The method of claim 35, further comprising: repeating steps (a)-(d) such that the product alcohol in the fermentation vessel is maintained at less than about 40 g/L during the fermentation in the fermentation vessel.
 46. A method of recovering a product alcohol from an absorption liquid phase and regenerating the absorption liquid phase, comprising: (a) pumping from an absorber an absorption liquid phase comprising an absorption liquid, water, product alcohol, and optionally CO₂, to a higher pressure than a pressure in the absorber; (b) optionally, heating the absorption liquid phase; (c) feeding the absorption liquid phase to a multi-stage distillation column comprising a stripping section and optionally a rectification section; (d) operating the distillation column under conditions such that a bottoms product comprising the absorption liquid and a vapor phase comprising a mixture of water, product alcohol, and optionally CO₂ are produced; (e) recovering the bottoms product comprising the absorption liquid phase from the distillation column; and (f) recovering the water, the product alcohol and optionally CO₂ from the vapor phase.
 47. The method of claim 46, further comprising: (g) causing to be separated the constituent parts of the vapor phase from (f) by condensation, distillation, decantation, or a combination thereof.
 48. The method of claim 46, further comprising: (g) at least partially condensing the vapor phase produced in step (d) to form a two liquid phase mixture; (h) passing the liquid phase mixture to a decanter wherein the liquid phase mixture is separated into an aqueous phase and an organic phase (i) passing at least portion of the aqueous phase to the rectification section of the distillation column of step (c); (j) removing a liquid side stream from the rectification section of the distillation column and returning it to a vacuum flash vessel configured to receive a fermentation liquid feed stream comprising product alcohol, water, and optionally CO₂; (k) passing at least a portion of the organic phase to a second distillation column comprising a stripping section; (l) withdrawing a product alcohol from a bottom of the second distillation column; (m) withdrawing vapors from a top of the second distillation column; (n) causing the vapors from (m) to be cooled so that the vapors partially condense to form two liquid phases; and (o) passing the liquid phases from (n) to a decanter. 49-52. (canceled)
 53. The method of claim 52, wherein said vapor streams are 10 to 100 parts by mass butanol to one part carbon dioxide.
 54. The method of claim 46, wherein the pressure of the vapor phase comprises 1 to 100 parts by mass butanol to one part carbon dioxide and the pressure is 1 to 30 psig.
 55. The method of claim 54, wherein said pressure is 0.9 to 1.2 atmospheres.
 56. A vapor stream of claim
 52. 57. (canceled) 